US20060273592A1 - Power unit - Google Patents
Power unit Download PDFInfo
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- US20060273592A1 US20060273592A1 US11/445,253 US44525306A US2006273592A1 US 20060273592 A1 US20060273592 A1 US 20060273592A1 US 44525306 A US44525306 A US 44525306A US 2006273592 A1 US2006273592 A1 US 2006273592A1
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- Prior art keywords
- power
- semiconductor devices
- electronic semiconductor
- power modules
- modules
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M7/00—Conversion of AC power input into DC power output; Conversion of DC power input into AC power output
- H02M7/003—Constructional details, e.g. physical layout, assembly, wiring or busbar connections
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M7/00—Conversion of AC power input into DC power output; Conversion of DC power input into AC power output
- H02M7/42—Conversion of DC power input into AC power output without possibility of reversal
- H02M7/44—Conversion of DC power input into AC power output without possibility of reversal by static converters
- H02M7/48—Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
- H02M7/53—Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
- H02M7/537—Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters
- H02M7/5387—Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only, e.g. single switched pulse inverters in a bridge configuration
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M1/00—Details of apparatus for conversion
- H02M1/0067—Converter structures employing plural converter units, other than for parallel operation of the units on a single load
- H02M1/007—Plural converter units in cascade
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- H10W72/884—
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- H10W74/00—
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- H10W90/756—
Definitions
- the present invention relates generally to a power unit used as a power converter for controllably driving an electric motor or a generator mounted on a mobile unit, such as a motor vehicle, and more particularly, to a power unit including power modules which incorporate power electronic semiconductor devices.
- Hybrid vehicles have recently been marketed in automotive industry.
- the hybrid vehicles are typically equipped with a power converter which converts direct current (DC) power fed from an onboard battery into alternating current (AC) power to drive a motor and converts AC power produced by transforming kinetic energy into electrical energy by a generator during braking into DC power to charge the battery.
- DC direct current
- AC alternating current
- Japanese Patent Application Publication No. 2003-204606 discloses a conventional hybrid vehicle provided with a pair of rotating electric machines each of which can be operated either as a motor or as a generator.
- the two rotating electric machines are individually connected to semiconductor inverters which serve as driving circuits of the respective rotating electric machines.
- the amount of electric power generated by the generator and the amount of motive power produced by the motor are controlled by turning on and off switching devices of each of the inverters which are interconnected by a common power line.
- the aforementioned inverters for controllably switching the two rotating electric machines between power running mode (motor mode) and regenerative running mode (generator mode) each employ a circuit configuration which includes as a minimum functional unit a pair of power electronic semiconductor devices, that is, an insulated-gate bipolar transistor (IGBT) and a freewheeling diode.
- This circuit configuration includes two such semiconductor device pairs which control flows of electric current in the power running mode and the regenerative running mode in different ways independently of each other.
- a total of six minimum functional units or six semiconductor device pairs
- six semiconductor device pairs are packaged in a plastic power module by insert molding and this power module is mounted on a heat sink, forming a power unit of the vehicle.
- an object of the invention to provide an economical power unit with a reduced number of components which need to be replaced and disposed of in case of a failure of any power electronic semiconductor device. It is another object of the invention to provide an easy-to-manufacture module-type power unit which offers excellent mechanical durability and less potential for the occurrence of deformation or a crack in a plastic package.
- a power unit used as a power converter for controllably driving a plurality of rotating electric machines which are switchable between motor mode and generator mode includes a plurality of power modules for controlling individual phases of the plurality of rotating electric machines, and a heat sink on which the power modules are mounted.
- Each of the power modules includes a plurality of power electronic semiconductor devices, each having electrodes on top and bottom sides thereof, a metal block disposed on the bottom side of the power electronic semiconductor devices, electrically conductive device bonding layers disposed between the bottom-side electrodes of the power electronic semiconductor devices and the metal block in direct contact therewith, bottom-side electrode leads connected to the bottom-side electrodes of the respective power electronic semiconductor devices, top-side electrode leads connected to the top-side electrodes of the respective power electronic semiconductor devices, and a sealing plastic body sealing the metal block and the power electronic semiconductor devices with the bottom-side electrode leads and the top-side electrode leads extending outward from the sealing plastic body.
- the power unit can be manufactured by a simple process as at least three power modules are arranged side by side with the three main terminals of each of the three power modules aligned in one direction and connected to the conductors embedded in the terminal block. Additionally, as the terminal block is provided as a discrete component separate from the power modules, the power unit has excellent mechanical durability.
- FIG. 1 is a circuit diagram showing an internal circuit configuration of a power unit according to a first embodiment of the invention
- FIG. 3 is a plan view of one power module of the power unit of the first embodiment
- FIG. 4A is a cross-sectional view showing an internal configuration of the power module of the power unit of the first embodiment taken along lines A-A of FIG. 3 ;
- FIG. 4B is a cross-sectional view showing the internal configuration of the power module of the power unit of the first embodiment taken along lines B-B of FIG. 3 ;
- FIG. 5 is a plan view of a power unit according to a second embodiment of the invention showing in particular an arrangement of constituent components thereof;
- FIG. 6 is a circuit diagram showing an internal circuit configuration of a power unit according to a third embodiment of the invention.
- a hybrid vehicle is equipped with a power converter which works as an inverter for converting DC power fed from an onboard battery into AC power to drive a motor and as a converter (rectifier) for converting AC power produced by transforming kinetic energy of the vehicle into electrical energy by a generator during braking into DC power to charge the battery.
- the hybrid vehicle is provided with a pair of rotating electric machines 11 , 12 each of which can be operated either as a motor or as a generator.
- one of these rotating electric machines 11 , 12 is run as a motor while the other is run as a generator.
- both of the rotating electric machines 11 , 12 are operated as motors or as generators at the same time.
- This kind of rotating electric machines are conventionally operated in this way in a controlled fashion by a module-type power converter, or a power module, incorporating power electronic semiconductor devices.
- This power module is mounted on a heat sink to form the power unit of the embodiment.
- FIG. 1 is a circuit diagram showing an internal circuit configuration of the power unit according to the first embodiment of the invention for controllably driving the two rotating electric machines 11 , 12 each of which can be operated either as a motor or as a generator when switched between power running mode (motor mode) and regenerative running mode (generator mode).
- Main terminals 7 , 8 , 9 for carrying electric currents to and from the power modules 6 extend from one side of each of the power modules 6 as shown in FIG. 3 .
- Three of the six power modules 6 are arranged side by side with the main terminals 7 , 8 , 9 thereof aligned in one direction and joined to a terminal block 10 , while the other three power modules 6 are arranged side by side with the main terminals 7 , 8 , 9 thereof aligned in the opposite direction and joined to another terminal block 10 as shown in FIG. 2 .
- the main terminals 7 are negative electrode (N-side) terminals
- the main terminals 8 are positive electrode (P-side) terminals
- the main terminals 9 are rotating-machine-side terminals.
- Each terminal block 10 has built-in conductors through which the rotating-machine-side terminals 9 are connected to ends of three-phase field coils (U-, V- and W-phases) of one of the rotating electric machines 11 , 12 .
- the power unit of the embodiment further includes a DC-DC converter including an inductor 13 made of a coil or a transformer and a power module 14 in which high-frequency switches (e.g., IGBTs) 14 a and a commutating diode 14 b are assembled in a single package.
- the DC-DC converter and the six power modules 6 are connected to the two terminal blocks 10 which are together mounted on a heat sink 17 .
- FIG. 1 Designated by the reference numerals 15 and 16 in FIG. 1 are a smoothing capacitor and a battery, respectively.
- FIG. 1 shown by small solid circles in FIG. 1 are connecting points where electrodes of the individual electric components are electrically and mechanically joined to corresponding parts of a conductor wiring.
- the electric components are fixed to the heat sink 17 by nuts and bolts.
- FIG. 2 is a plan view of the power unit of the first embodiment showing in particular an exemplary layout of the components of the power unit. It is to be noted that the smoothing capacitor 15 and the battery 16 are not depicted in FIG. 2 .
- the main terminals 7 , 8 , 9 extend from one side of each of the power modules 6 , the three power modules 6 being arranged side by side with the main terminals 7 , 8 , 9 thereof aligned in one direction and joined to one terminal block 10 and the other three power modules 6 being arranged side by side with the main terminals 7 , 8 , 9 thereof aligned in the opposite direction and joined to the other terminal block 10 .
- a P-side conductor 10 a, an N-side conductor 10 b, and rotating-machine-side phase conductors 10 cu, 10 cv, 10 cw connected to the U-, V- and W-phase field coils of the rotating electric machine 11 or 12 are embedded in each of the two terminal blocks 10 .
- the N-side terminals 7 and the P-side terminals 8 are connected to the N-side conductor 10 b and the P-side conductor 10 a of each terminal block 10 , respectively, and the rotating-machine-side terminals 9 of the individual power modules 6 are connected to the corresponding rotating-machine-side phase conductors 10 cu, 10 cv, 10 cw.
- the inductor 13 and the power module 14 together constituting the DC-DC converter are also arranged side by side with main terminals thereof aligned in one direction and connected to conductors 18 a, 18 b, 18 c, 18 d embedded in a terminal block 18 .
- the power unit of the present embodiment includes a total of six power modules 6
- the number of the power modules 6 is not necessarily limited to six. If the withstand voltage or current capacity of the power electronic semiconductor devices 1 - 4 constituting the power modules 6 is insufficient due to large power requirements, for example, a desired number of parallel-connected power modules 6 may be connected to each phase of the rotating electric machines 11 , 12 to provide increased withstand voltage and current capacity ratings.
- the number of the power modules 6 mounted on the power unit may be any multiple of three so that each of the three phases is provided with a plurality of power modules 6 .
- Gates of the IGBTs 1 , 3 built in the six power modules 6 for driving the two rotating electric machines 11 , 12 are controlled by an unillustrated IGBT control circuit to generate voltages necessary for producing a forward or reverse torque to be applied to the rotating electric machines 11 , 12 or for running the rotating electric machines 11 , 12 in a forward or reverse direction at a desired speed from the aforementioned increased voltage by using a pulse width modulation (PWM) technique.
- PWM pulse width modulation
- FIG. 3 is a plan view of each power module 6 incorporated in the power unit
- FIG. 4A is a cross-sectional view taken along lines A-A of FIG. 3
- FIG. 4B is a cross-sectional view taken along lines B-B of FIG. 3 .
- the aforementioned power electronic semiconductor devices including the IGBTs 1 , 3 and the freewheeling diodes 2 , 4 have electrodes on top and bottom sides which are affixed to a metal block 22 via respective electrically conductive device bonding layers 21 .
- the electrically conductive device bonding layers 21 are made of an electrically conductive bonding agent, such as a soldering material or silver paste, but not limited to any particular material.
- top-side electrodes of the power electronic semiconductor devices 20 are connected to top-side electrode leads 24 via bonding wires 23 made of thin metal wires, for instance, and bottom-side electrode leads 26 of the power electronic semiconductor devices 20 are affixed to the metal block 22 via electrically conductive lead bonding layers 25 . Since the bottom-side electrodes and the bottom-side electrode leads 26 of the power electronic semiconductor devices 20 are together joined to the metal block 22 , the bottom-side electrodes and the bottom-side electrode leads 26 are interconnected via the metal block 22 .
- the top-side electrode leads 24 and the bottom-side electrode leads 26 are made of thin metal plates. As illustrated in FIG. 4A , the bottom-side electrode lead 26 corresponds to the N-side terminal 7 of each power module 6 , and as illustrated in FIG. 4B , the top-side electrode lead 24 connected to the top-side electrode of the power electronic semiconductor device 20 (freewheeling diode 2 ) corresponds to the rotating-machine-side terminal 9 of each power module 6 .
- the individual power electronic semiconductor devices 20 of each power module 6 are packaged by a sealing plastic 27 in such a manner that the sealing plastic 27 covers the metal block 22 and the power electronic semiconductor devices 20 with the top-side electrode leads 24 and the bottom-side electrode lead 26 extending outward.
- the power electronic semiconductor devices 20 ( 1 - 4 ), which are heat-generating elements, of each power module 6 are disposed above the metal block 22 with the electrically conductive device bonding layers 21 placed in between in the present embodiment, heat generated by the power electronic semiconductor devices 20 is transferred to the metal block 22 through the electrically conductive device bonding layers 21 having a high thermal conductivity.
- heat is transferred from the power electronic semiconductor devices 20 to the metal block 22 without passing through a layer of the sealing plastic 27 having a low thermal conductivity.
- a greater amount of heat flows into the metal block 22 per unit time and spreads out in the metal block 22 which provides an enlarged cross-sectional area for heat flux to flow through to the bottom of each power module 6 . It is therefore possible to make the power modules 6 featuring excellent heat dissipating performance and compact design as well as high capacity, yet providing economic advantages as it is not necessary to use an expensive sealing plastic material having a high thermal conductivity according to structure of the embodiment.
- the above-described power module structure suited for achieving excellent heat dissipating performance and compact design makes it possible to produce the power modules 6 needed for controllably driving the individual phases of the two rotating electric machines 11 , 12 in compact size with high reliability.
- the power electronic semiconductor devices 20 are packaged in the six separate power modules 6 in the structure of the present embodiment. This makes it possible to reduce the size of each power module 6 and reduce the potential for the occurrence of deformation or a crack in a plastic case of each power module 6 due to a difference in linear expansion coefficient between different materials of internal conductors and the plastic case. Additionally, the power modules 6 are small-sized and the internal conductors thereof are formed in a relatively simple pattern so that it is easy to fix the conductors at specified positions and perform insert molding operation for manufacturing the power modules 6 .
- the aforementioned structure of the embodiment is such that the five conductors 10 a, 10 b, 10 cu, 10 cv, 10 cw are arranged in each of the terminal blocks 10 in an electrically insulated fashion as the conductors 10 a, 10 b, 10 cu, 10 cv, 10 cw are embedded in grooves formed in an insulator body or molded therein by insert molding, for instance.
- the P-side conductor 10 a, the N-side conductor 10 b as well as the rotating-machine-side phase conductors 10 cu, 10 cv, 10 cw connected to the U-, V- and W-phase field coils of one of the rotating electric machines 11 , 12 are together formed in this way in each of the terminal blocks 10 .
- the conductors 10 a, 10 b, 10 cu, 10 cv, 10 cw can be laid in generally straight lines. Therefore, the conductors 10 a, 10 b, 10 cu, 10 cv, 10 cw can be fixed at the specified positions with ease by the insert molding operation, for example, making it possible to manufacture the terminal blocks 10 in a simple and easy way.
- the N-side terminals 7 and the P-side terminals 8 are connected to the N-side conductor 10 b and the P-side conductor 10 a of each terminal block 10 , respectively, and the main terminals of the inductor 13 and the power module 14 are connected to the two conductors 10 d, 10 e.
- the second embodiment eliminates the need for providing a separate terminal block for connecting the DC-DC converter and thereby simplifies the structure of the power unit while offering the same advantages as the first embodiment.
- the power unit of the third embodiment is provided with only one terminal block 10 and all six power modules 6 are connected to this terminal block 10 .
- three each power modules 6 are arranged side by side on opposite sides of the terminal block 10 such that main terminals 7 , 8 , 9 of the three each power modules 6 arranged side by side are directed against one side of the terminal block 10 .
- One pair each of P-side conductors 10 a and N-side conductors 10 b and three pairs of rotating-machine-side phase conductors 10 cu, 10 cv and 10 cw connected to U-, V- and W-phase field coils of the rotating electric machines 11 , 12 are embedded in the terminal block 10 .
- the N-side terminals 7 and the P-side terminals 8 are connected to the N-side conductors 10 b and the P-side conductors 10 a of the terminal block 10 , respectively, and the rotating-machine-side terminals 9 are connected to the corresponding rotating-machine-side phase conductors 10 cu, 10 cv and 10 cw.
- the third embodiment makes it possible to connect all the power modules 6 to the single terminal block 10 and thereby simplifies the structure of the power unit while offering the same advantages as the first embodiment.
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Abstract
A power unit includes a plurality of power modules for controlling individual phases of a pair of rotating electric machines and a heat sink on which the power modules are mounted. Each of the power modules includes a metal block, four power electronic semiconductor devices which are heat-generating elements mounted on the metal block with electrically conductive device bonding layers placed in between, and a plastic case. The plastic case is made of a plastic material sealing the power electronic semiconductor devices and the metal block in a single package with leads connected to top- and bottom-side electrodes of the power electronic semiconductor devices extending outward from the plastic case.
Description
- 1. Field of the Invention
- The present invention relates generally to a power unit used as a power converter for controllably driving an electric motor or a generator mounted on a mobile unit, such as a motor vehicle, and more particularly, to a power unit including power modules which incorporate power electronic semiconductor devices.
- 2. Description of the Background Art
- Hybrid vehicles have recently been marketed in automotive industry. The hybrid vehicles are typically equipped with a power converter which converts direct current (DC) power fed from an onboard battery into alternating current (AC) power to drive a motor and converts AC power produced by transforming kinetic energy into electrical energy by a generator during braking into DC power to charge the battery.
- As an example, Japanese Patent Application Publication No. 2003-204606 discloses a conventional hybrid vehicle provided with a pair of rotating electric machines each of which can be operated either as a motor or as a generator. The two rotating electric machines are individually connected to semiconductor inverters which serve as driving circuits of the respective rotating electric machines. The amount of electric power generated by the generator and the amount of motive power produced by the motor are controlled by turning on and off switching devices of each of the inverters which are interconnected by a common power line.
- The aforementioned inverters (i.e., power converters) for controllably switching the two rotating electric machines between power running mode (motor mode) and regenerative running mode (generator mode) each employ a circuit configuration which includes as a minimum functional unit a pair of power electronic semiconductor devices, that is, an insulated-gate bipolar transistor (IGBT) and a freewheeling diode. This circuit configuration includes two such semiconductor device pairs which control flows of electric current in the power running mode and the regenerative running mode in different ways independently of each other. For controlling the two rotating electric machines which serve as three-phase motor-generators, a total of six minimum functional units (or six semiconductor device pairs) are required. In the aforementioned conventional hybrid vehicle, six semiconductor device pairs are packaged in a plastic power module by insert molding and this power module is mounted on a heat sink, forming a power unit of the vehicle.
- In the aforementioned power unit of the conventional hybrid vehicle, six power electronic semiconductor units constituting two power converters are packaged in a single power module as mentioned above. Therefore, even when only one of the power electronic semiconductor devices fails, it is necessary to replace the complete power module including even the properly working semiconductor devices, resulting in an economic loss.
- Additionally, a plastic case of the power module incorporating the six power electronic semiconductor units is so large-sized that deformation or a crack tends to occur in the plastic case due to a difference in linear expansion coefficient between different materials of conductors carrying the electric power and the plastic case. A further problem of the above-described prior art configuration is that it is difficult to arrange and fix the conductors at specified positions to form a much complicated conductor pattern in a short time during an insert molding process.
- Intended to overcome the aforementioned problems of the prior art, it is an object of the invention to provide an economical power unit with a reduced number of components which need to be replaced and disposed of in case of a failure of any power electronic semiconductor device. It is another object of the invention to provide an easy-to-manufacture module-type power unit which offers excellent mechanical durability and less potential for the occurrence of deformation or a crack in a plastic package.
- In one feature of the invention, a power unit used as a power converter for controllably driving a plurality of rotating electric machines which are switchable between motor mode and generator mode includes a plurality of power modules for controlling individual phases of the plurality of rotating electric machines, and a heat sink on which the power modules are mounted. Each of the power modules includes a plurality of power electronic semiconductor devices, each having electrodes on top and bottom sides thereof, a metal block disposed on the bottom side of the power electronic semiconductor devices, electrically conductive device bonding layers disposed between the bottom-side electrodes of the power electronic semiconductor devices and the metal block in direct contact therewith, bottom-side electrode leads connected to the bottom-side electrodes of the respective power electronic semiconductor devices, top-side electrode leads connected to the top-side electrodes of the respective power electronic semiconductor devices, and a sealing plastic body sealing the metal block and the power electronic semiconductor devices with the bottom-side electrode leads and the top-side electrode leads extending outward from the sealing plastic body.
- Each of the power modules of this power unit is structured by mounting the power electronic semiconductor devices on the metal block with the electrically conductive device bonding layers placed in between and sealing the metal block and the power electronic semiconductor devices in a plastic case with the top- and bottom-side electrode leads extending outward from the package. This structure makes it possible to produce compact yet high-capacity power modules featuring improved heat dissipating performance. According to this structure of the invention, it is possible to manufacture a power unit provided with compact power modules for controlling individual phases of a plurality of rotating electric machines with high reliability, the power modules being mounted on a heat sink. A reduction in size of each power module serves to prevent the occurrence of deformation and cracks in the plastic case thereof.
- Additionally, since the multiple power modules are provided for controlling the individual phases of each rotating electric machine, it is possible to reduce the number of components, and in particular expensive components like power electronic semiconductor devices, that should be replaced and disposed of in case of a failure, thus providing an economic advantage.
- In another feature of the invention, a power unit used as a power converter for controllably driving a plurality of rotating electric machines which are switchable between motor mode and generator mode includes a plurality of power modules for controlling individual phases of the plurality of rotating electric machines, each of the power modules including a plurality of power electronic semiconductor devices, a heat sink on which the power modules are mounted, and a terminal block in which conductors are embedded. In this power unit, at least three of the power modules are arranged side by side with three main terminals of each of the at least three power modules aligned in one direction, and the main terminals of the power modules arranged side by side are connected to the conductors of the terminal block.
- Since the multiple power modules are provided for controlling the individual phases of each rotating electric machine in this power unit of the invention, it is possible to reduce the number of components, and in particular expensive components like power electronic semiconductor devices, that should be replaced and disposed of in case of a failure, thus providing an economic advantage. Also, a reduction in size of each power module serves to prevent the occurrence of deformation and cracks in the plastic case thereof. According to this structure of the invention, it is possible to assemble each power module in a short time by a simple process, so that a plurality of power modules can be simultaneously manufactured with ease.
- Furthermore, the power unit can be manufactured by a simple process as at least three power modules are arranged side by side with the three main terminals of each of the three power modules aligned in one direction and connected to the conductors embedded in the terminal block. Additionally, as the terminal block is provided as a discrete component separate from the power modules, the power unit has excellent mechanical durability.
- These and other objects, features and advantages of the invention will become more apparent upon reading the following detailed description in conjunction with the accompanying drawings.
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FIG. 1 is a circuit diagram showing an internal circuit configuration of a power unit according to a first embodiment of the invention; -
FIG. 2 is a plan view of the power unit of the first embodiment showing in particular an arrangement of constituent components thereof; -
FIG. 3 is a plan view of one power module of the power unit of the first embodiment; -
FIG. 4A is a cross-sectional view showing an internal configuration of the power module of the power unit of the first embodiment taken along lines A-A ofFIG. 3 ; -
FIG. 4B is a cross-sectional view showing the internal configuration of the power module of the power unit of the first embodiment taken along lines B-B ofFIG. 3 ; -
FIG. 5 is a plan view of a power unit according to a second embodiment of the invention showing in particular an arrangement of constituent components thereof; -
FIG. 6 is a circuit diagram showing an internal circuit configuration of a power unit according to a third embodiment of the invention; and -
FIG. 7 is a plan view of the power unit of the third embodiment showing in particular an arrangement of constituent components thereof. - A power unit mounted on a hybrid vehicle according to a first embodiment of the present invention is described with reference to FIGS. 1 to 3.
- Generally, a hybrid vehicle is equipped with a power converter which works as an inverter for converting DC power fed from an onboard battery into AC power to drive a motor and as a converter (rectifier) for converting AC power produced by transforming kinetic energy of the vehicle into electrical energy by a generator during braking into DC power to charge the battery. In this embodiment, the hybrid vehicle is provided with a pair of rotating
11, 12 each of which can be operated either as a motor or as a generator. In one form of the invention, one of these rotatingelectric machines 11, 12 is run as a motor while the other is run as a generator. In another form of the invention, both of the rotatingelectric machines 11, 12 are operated as motors or as generators at the same time. This kind of rotating electric machines are conventionally operated in this way in a controlled fashion by a module-type power converter, or a power module, incorporating power electronic semiconductor devices. This power module is mounted on a heat sink to form the power unit of the embodiment.electric machines -
FIG. 1 is a circuit diagram showing an internal circuit configuration of the power unit according to the first embodiment of the invention for controllably driving the two rotating 11, 12 each of which can be operated either as a motor or as a generator when switched between power running mode (motor mode) and regenerative running mode (generator mode).electric machines - Referring to
FIG. 1 , the power unit includes a total of six power electronic semiconductor units 5 each of which serves as a minimum functional unit for controlling operation in the power running mode and the regenerative running mode, each power electronic semiconductor unit 5 incorporating a pair of power electronic semiconductor devices, that is, anIGBT 1 and afreewheeling diode 2, or anIGBT 3 and afreewheeling diode 4. The power electronic semiconductor devices 1-4 of each power electronic semiconductor unit 5 are assembled and sealed in a single plastic package to form apower module 6. -
7, 8, 9 for carrying electric currents to and from theMain terminals power modules 6 extend from one side of each of thepower modules 6 as shown inFIG. 3 . Three of the sixpower modules 6 are arranged side by side with the 7, 8, 9 thereof aligned in one direction and joined to amain terminals terminal block 10, while the other threepower modules 6 are arranged side by side with the 7, 8, 9 thereof aligned in the opposite direction and joined to anothermain terminals terminal block 10 as shown inFIG. 2 . Here, themain terminals 7 are negative electrode (N-side) terminals, themain terminals 8 are positive electrode (P-side) terminals and themain terminals 9 are rotating-machine-side terminals. Eachterminal block 10 has built-in conductors through which the rotating-machine-side terminals 9 are connected to ends of three-phase field coils (U-, V- and W-phases) of one of the rotating 11, 12.electric machines - The power unit of the embodiment further includes a DC-DC converter including an
inductor 13 made of a coil or a transformer and apower module 14 in which high-frequency switches (e.g., IGBTs) 14 a and a commutatingdiode 14 b are assembled in a single package. The DC-DC converter and the sixpower modules 6 are connected to the twoterminal blocks 10 which are together mounted on aheat sink 17. - Designated by the
15 and 16 inreference numerals FIG. 1 are a smoothing capacitor and a battery, respectively. In addition, shown by small solid circles inFIG. 1 are connecting points where electrodes of the individual electric components are electrically and mechanically joined to corresponding parts of a conductor wiring. In this embodiment, the electric components are fixed to theheat sink 17 by nuts and bolts. -
FIG. 2 is a plan view of the power unit of the first embodiment showing in particular an exemplary layout of the components of the power unit. It is to be noted that the smoothingcapacitor 15 and thebattery 16 are not depicted inFIG. 2 . - As already mentioned, the
7, 8, 9 (the N-main terminals side terminals 7, the P-side terminals 8 and the rotating-machine-side terminals 9) extend from one side of each of thepower modules 6, the threepower modules 6 being arranged side by side with the 7, 8, 9 thereof aligned in one direction and joined to onemain terminals terminal block 10 and the other threepower modules 6 being arranged side by side with the 7, 8, 9 thereof aligned in the opposite direction and joined to the othermain terminals terminal block 10. A P-side conductor 10 a, an N-side conductor 10 b, and rotating-machine-side phase conductors 10 cu, 10 cv, 10 cw connected to the U-, V- and W-phase field coils of the rotating 11 or 12 are embedded in each of the two terminal blocks 10. The N-electric machine side terminals 7 and the P-side terminals 8 are connected to the N-side conductor 10 b and the P-side conductor 10 a of eachterminal block 10, respectively, and the rotating-machine-side terminals 9 of theindividual power modules 6 are connected to the corresponding rotating-machine-side phase conductors 10 cu, 10 cv, 10 cw. - The
inductor 13 and thepower module 14 together constituting the DC-DC converter are also arranged side by side with main terminals thereof aligned in one direction and connected to 18 a, 18 b, 18 c, 18 d embedded in aconductors terminal block 18. - While the power unit of the present embodiment includes a total of six
power modules 6, the number of thepower modules 6 is not necessarily limited to six. If the withstand voltage or current capacity of the power electronic semiconductor devices 1-4 constituting thepower modules 6 is insufficient due to large power requirements, for example, a desired number of parallel-connectedpower modules 6 may be connected to each phase of the rotating 11, 12 to provide increased withstand voltage and current capacity ratings. Specifically, the number of theelectric machines power modules 6 mounted on the power unit may be any multiple of three so that each of the three phases is provided with a plurality ofpower modules 6. - Now, the working of the power unit is described. The DC-DC converter made up of the
inductor 13 and thepower module 14 connected to thebattery 16 stores electric energy when an electric current flows through theinductor 13 with the high-frequency switches 14 a held in an ON state. The high-frequency switches 14 a of the DC-DC converter are turned on and off by controlling a gate of each high-frequency switch 14 a by means of an unillustrated control circuit. When the high-frequency switches 14 a are turned off, the electric energy stored in theinductor 13 flows through thepower module 14 b, producing a voltage increased to a specified level. If the voltage is increased, it is possible to lower the amount of current necessary for feeding the same amount of electric power, thereby reducing the amount of heat loss. This in turn serves to improve efficiency of the power unit (power supply system). - Gates of the
1, 3 built in the sixIGBTs power modules 6 for driving the two rotating 11, 12 are controlled by an unillustrated IGBT control circuit to generate voltages necessary for producing a forward or reverse torque to be applied to the rotatingelectric machines 11, 12 or for running the rotatingelectric machines 11, 12 in a forward or reverse direction at a desired speed from the aforementioned increased voltage by using a pulse width modulation (PWM) technique.electric machines - While the
1, 3 of the individual phases are successively turned on and off by PWM operation, a non-uniform current distribution is likely to occur in a power carrying conductor system of theIGBTs battery 16. It is however possible to reduce current distortion components and thereby prolong the service life of thebattery 16 in this embodiment. This is because the smoothingcapacitor 15 is parallel-connected between both electrodes of thebattery 16. - The configuration of each of the
aforementioned power modules 6 is now described with reference toFIGS. 3, 4A and 4B, in whichFIG. 3 is a plan view of eachpower module 6 incorporated in the power unit,FIG. 4A is a cross-sectional view taken along lines A-A ofFIG. 3 , andFIG. 4B is a cross-sectional view taken along lines B-B ofFIG. 3 . - As shown in these Figures, the aforementioned power electronic semiconductor devices (hereinafter referred to as the power electronic semiconductor devices 20) including the
1, 3 and theIGBTs 2, 4 have electrodes on top and bottom sides which are affixed to afreewheeling diodes metal block 22 via respective electrically conductive device bonding layers 21. The electrically conductive device bonding layers 21 are made of an electrically conductive bonding agent, such as a soldering material or silver paste, but not limited to any particular material. The top-side electrodes of the powerelectronic semiconductor devices 20 are connected to top-side electrode leads 24 viabonding wires 23 made of thin metal wires, for instance, and bottom-side electrode leads 26 of the powerelectronic semiconductor devices 20 are affixed to themetal block 22 via electrically conductive lead bonding layers 25. Since the bottom-side electrodes and the bottom-side electrode leads 26 of the powerelectronic semiconductor devices 20 are together joined to themetal block 22, the bottom-side electrodes and the bottom-side electrode leads 26 are interconnected via themetal block 22. - The top-side electrode leads 24 and the bottom-side electrode leads 26 are made of thin metal plates. As illustrated in
FIG. 4A , the bottom-side electrode lead 26 corresponds to the N-side terminal 7 of eachpower module 6, and as illustrated inFIG. 4B , the top-side electrode lead 24 connected to the top-side electrode of the power electronic semiconductor device 20 (freewheeling diode 2) corresponds to the rotating-machine-side terminal 9 of eachpower module 6. - The individual power
electronic semiconductor devices 20 of eachpower module 6 are packaged by a sealingplastic 27 in such a manner that the sealingplastic 27 covers themetal block 22 and the powerelectronic semiconductor devices 20 with the top-side electrode leads 24 and the bottom-side electrode lead 26 extending outward. - Since the power electronic semiconductor devices 20 (1-4), which are heat-generating elements, of each
power module 6 are disposed above themetal block 22 with the electrically conductive device bonding layers 21 placed in between in the present embodiment, heat generated by the powerelectronic semiconductor devices 20 is transferred to themetal block 22 through the electrically conductive device bonding layers 21 having a high thermal conductivity. In this structure of the embodiment, heat is transferred from the powerelectronic semiconductor devices 20 to themetal block 22 without passing through a layer of the sealingplastic 27 having a low thermal conductivity. Thus, a greater amount of heat flows into themetal block 22 per unit time and spreads out in themetal block 22 which provides an enlarged cross-sectional area for heat flux to flow through to the bottom of eachpower module 6. It is therefore possible to make thepower modules 6 featuring excellent heat dissipating performance and compact design as well as high capacity, yet providing economic advantages as it is not necessary to use an expensive sealing plastic material having a high thermal conductivity according to structure of the embodiment. - The above-described power module structure suited for achieving excellent heat dissipating performance and compact design makes it possible to produce the
power modules 6 needed for controllably driving the individual phases of the two rotating 11, 12 in compact size with high reliability.electric machines - When any of the
power modules 6 fails during the manufacture of the power unit, for instance, it is not necessary to replace all of thepower modules 6 but only thefaulty power module 6 needs to be replaced in the above-described structure of the embodiment, because the power unit is provided with thediscrete power modules 6 for driving the individual phases of the two rotating 11, 12. This feature of the embodiment makes it possible to reduce the number of components to be replaced and disposed of in case of a failure, thus providing an economic advantage.electric machines - Compared to the earlier-mentioned conventional power unit in which six power electronic semiconductor units are packaged in a single power module, the power
electronic semiconductor devices 20 are packaged in the sixseparate power modules 6 in the structure of the present embodiment. This makes it possible to reduce the size of eachpower module 6 and reduce the potential for the occurrence of deformation or a crack in a plastic case of eachpower module 6 due to a difference in linear expansion coefficient between different materials of internal conductors and the plastic case. Additionally, thepower modules 6 are small-sized and the internal conductors thereof are formed in a relatively simple pattern so that it is easy to fix the conductors at specified positions and perform insert molding operation for manufacturing thepower modules 6. - In this embodiment, the
7, 8, 9 of eachmain terminals power module 6 extend from one side thereof, and three ormore power modules 6 are arranged side by side with the individual 7, 8, 9 aligned in one direction. The N-main terminals side terminals 7 and the P-side terminals 8 are connected to the N-side conductor 10 b and the P-side conductor 10 a of one of twoterminal blocks 10, respectively, and the rotating-machine-side terminals 9 of theindividual power modules 6 are connected to the corresponding rotating-machine-side phase conductors 10 cu, 10 cv, 10 cw as discussed earlier. As there are provided two separate terminal blocks 10 for connecting input/output lines of theindividual power modules 6, the power unit of the embodiment can be structured to provide excellent mechanical durability. - The aforementioned structure of the embodiment is such that the five
10 a, 10 b, 10 cu, 10 cv, 10 cw are arranged in each of the terminal blocks 10 in an electrically insulated fashion as theconductors 10 a, 10 b, 10 cu, 10 cv, 10 cw are embedded in grooves formed in an insulator body or molded therein by insert molding, for instance. The P-conductors side conductor 10 a, the N-side conductor 10 b as well as the rotating-machine-side phase conductors 10 cu, 10 cv, 10 cw connected to the U-, V- and W-phase field coils of one of the rotating 11, 12 are together formed in this way in each of the terminal blocks 10. Additionally, theelectric machines 10 a, 10 b, 10 cu, 10 cv, 10 cw can be laid in generally straight lines. Therefore, theconductors 10 a, 10 b, 10 cu, 10 cv, 10 cw can be fixed at the specified positions with ease by the insert molding operation, for example, making it possible to manufacture the terminal blocks 10 in a simple and easy way.conductors - Furthermore, even if deformation occurs in the
terminal block 10 due to a difference in linear expansion coefficient between the insulator body of theterminal block 10 and the 10 a, 10 b, 10 cu, 10 cv, 10 cw, minor differences in dimensional changes of these elements (conductors and plastic material) are absorbed by sliding action on boundary surfaces thereof, so that substantially no stress is produced in the individual elements. This helps prevent deformation and cracks in the insulator body, making it possible to manufacture the terminal blocks 10 having excellent mechanical durability and, thus, the power unit having increased mechanical durability.conductors -
FIG. 5 is a plan view of a power unit according to a second embodiment of the invention. While theinductor 13 and thepower module 14 constituting the DC-DC converter are connected to theterminal block 18 provided separately from the terminal blocks 10 to which thepower modules 6 are connected in the aforementioned first embodiment, theinductor 13 and thepower module 14 are arranged as illustrated inFIG. 5 in the power unit of the second embodiment. - In this embodiment, one of two
terminal blocks 10 to which three eachpower modules 6 are connected is elongated, and theinductor 13 and thepower module 14 together constituting a DC-DC converter are connected to theelongated terminal block 10. A P-side conductor 10 a, an N-side conductor 10 b, three rotating-machine-side phase conductors 10 cu, 10 cv, 10 cw and two 10 d, 10 e are embedded in this elongatedconductors terminal block 10. Theinductor 13 and thepower module 14 are arranged side by side with main terminals thereof aligned in one direction together with 7, 8, 9 of the threemain terminals power modules 6. The N-side terminals 7 and the P-side terminals 8 are connected to the N-side conductor 10 b and the P-side conductor 10 a of eachterminal block 10, respectively, and the main terminals of theinductor 13 and thepower module 14 are connected to the two 10 d, 10 e.conductors - The second embodiment eliminates the need for providing a separate terminal block for connecting the DC-DC converter and thereby simplifies the structure of the power unit while offering the same advantages as the first embodiment.
-
FIG. 6 is a circuit diagram showing an internal circuit configuration of a power unit according to a third embodiment of the invention, andFIG. 7 is a plan view of the power unit of the third embodiment showing in particular an arrangement of constituent components thereof, in which elements equivalent to those of the first embodiment are designated by the same reference numerals. - While the power unit is provided with the two
terminal blocks 10 for the rotating 11, 12 and three eachelectric machines power modules 6 are connected to the individual terminal blocks 10 in the aforementioned first embodiment, the power unit of the third embodiment is provided with only oneterminal block 10 and all sixpower modules 6 are connected to thisterminal block 10. As illustrated inFIGS. 6 and 7 , three eachpower modules 6 are arranged side by side on opposite sides of theterminal block 10 such that 7, 8, 9 of the three eachmain terminals power modules 6 arranged side by side are directed against one side of theterminal block 10. - One pair each of P-
side conductors 10 a and N-side conductors 10 b and three pairs of rotating-machine-side phase conductors 10 cu, 10 cv and 10 cw connected to U-, V- and W-phase field coils of the rotating 11, 12 are embedded in theelectric machines terminal block 10. The N-side terminals 7 and the P-side terminals 8 are connected to the N-side conductors 10 b and the P-side conductors 10 a of theterminal block 10, respectively, and the rotating-machine-side terminals 9 are connected to the corresponding rotating-machine-side phase conductors 10 cu, 10 cv and 10 cw. - The third embodiment makes it possible to connect all the
power modules 6 to thesingle terminal block 10 and thereby simplifies the structure of the power unit while offering the same advantages as the first embodiment.
Claims (5)
1. A power unit used as a power converter for controllably driving a plurality of rotating electric machines which are switchable between motor mode and generator mode, said power unit comprising:
a plurality of power modules for controlling individual phases of said plurality of rotating electric machines; and
a heat sink on which said power modules are mounted;
each of said power modules including:
a plurality of power electronic semiconductor devices, each having electrodes on top and bottom sides thereof;
a metal block disposed on the bottom side of said power electronic semiconductor devices;
electrically conductive device bonding layers disposed between the bottom-side electrodes of said power electronic semiconductor devices and said metal block in direct contact therewith;
bottom-side electrode leads connected to the bottom-side electrodes of said respective power electronic semiconductor devices;
top-side electrode leads connected to the top-side electrodes of said respective power electronic semiconductor devices; and
a sealing plastic body sealing said metal block and said power electronic semiconductor devices with said bottom-side electrode leads and said top-side electrode leads extending outward from said sealing plastic body.
2. The power unit according to claim 1 , wherein at least six power modules are mounted on said heat sink.
3. A power unit used as a power converter for controllably driving a plurality of rotating electric machines which are switchable between motor mode and generator mode, said power unit comprising:
a plurality of power modules for controlling individual phases of said plurality of rotating electric machines, each of said power modules including a plurality of power electronic semiconductor devices;
a heat sink on which said power modules are mounted; and
a terminal block in which conductors are embedded;
wherein at least three of said power modules are arranged side by side with three main terminals of each of said at least three power modules aligned in one direction, and the main terminals of said power modules arranged side by side are connected to the conductors of said terminal block.
4. The power unit according to claim 3 , wherein the conductors of said terminal block are a positive-side conductor, a negative-side conductor, and rotating-machine-side phase conductors connected to the individual phases of one of said rotating electric machines.
5. The power unit according to claim 3 , wherein at least six power modules are mounted on said heat sink.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JPJP2005-165397 | 2005-06-06 | ||
| JP2005165397A JP4127550B2 (en) | 2005-06-06 | 2005-06-06 | Power unit |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US20060273592A1 true US20060273592A1 (en) | 2006-12-07 |
Family
ID=37493431
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US11/445,253 Abandoned US20060273592A1 (en) | 2005-06-06 | 2006-06-02 | Power unit |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US20060273592A1 (en) |
| JP (1) | JP4127550B2 (en) |
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| US20080183361A1 (en) * | 2007-01-31 | 2008-07-31 | Katsuya Oyama | Controller for inverter |
| US20090097292A1 (en) * | 2007-07-20 | 2009-04-16 | Diversified Technology, Inc. | On-board vehicle power |
| US20090179721A1 (en) * | 2008-01-11 | 2009-07-16 | Ise Corporation | Cooled High Power Vehicle Inductor and Method |
| US20100117570A1 (en) * | 2007-02-13 | 2010-05-13 | Toyota Jidosha Kabushiki Kaisha | Power conversion device |
| US20110222244A1 (en) * | 2010-03-15 | 2011-09-15 | Omron Corporation | Power conditioner device and module substrate structure using the same |
| US20120008280A1 (en) * | 2006-04-27 | 2012-01-12 | Hitachi, Ltd. | Electric Circuit Device, Electric Circuit Module, and Power Converter |
| US20140265332A1 (en) * | 2013-03-12 | 2014-09-18 | Robert Bosch Gmbh | Electric machine in a motor vehicle having a rotational speed signal input |
| US20160126205A1 (en) * | 2014-11-04 | 2016-05-05 | Toyota Jidosha Kabushiki Kaisha | Semiconductor device and manufacturing method for the semiconductor device |
| US20160241156A1 (en) * | 2013-12-03 | 2016-08-18 | Mitsubishi Electric Corporation | Power conversion apparatus |
| EP2479881A4 (en) * | 2009-09-17 | 2016-12-21 | Toshiba Mitsubishi-Electric Ind Systems Corp | Electric power conversion apparatus |
| EP2555409A4 (en) * | 2010-03-31 | 2017-12-27 | Kabushiki Kaisha Toshiba | Electric vehicle control device |
| US20210327811A1 (en) * | 2020-04-20 | 2021-10-21 | Sungrow Power Supply Co., Ltd. | Inverter, And Power Unit And Power Module Applied Thereto |
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| JP2008206367A (en) * | 2007-02-22 | 2008-09-04 | Ihi Corp | Motor control driving device, and turbocharger with motor |
| KR101145640B1 (en) * | 2010-12-06 | 2012-05-23 | 기아자동차주식회사 | Power module for invertor |
| JP6667601B1 (en) * | 2018-11-15 | 2020-03-18 | 三菱電機株式会社 | Power converter |
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| US20120008280A1 (en) * | 2006-04-27 | 2012-01-12 | Hitachi, Ltd. | Electric Circuit Device, Electric Circuit Module, and Power Converter |
| US9307666B2 (en) | 2006-04-27 | 2016-04-05 | Hitachi, Ltd. | Electric circuit device, electric circuit module, and power converter |
| US8743548B2 (en) * | 2006-04-27 | 2014-06-03 | Hitachi, Ltd. | Electric circuit device, electric circuit module, and power converter |
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| CN102195454A (en) * | 2010-03-15 | 2011-09-21 | 欧姆龙株式会社 | Power conditioner device and module substrate structure using the same |
| EP2555409A4 (en) * | 2010-03-31 | 2017-12-27 | Kabushiki Kaisha Toshiba | Electric vehicle control device |
| US9885334B2 (en) * | 2013-03-12 | 2018-02-06 | Robert Bosch Gmbh | Electric machine in a motor vehicle having a rotational speed signal input |
| US20140265332A1 (en) * | 2013-03-12 | 2014-09-18 | Robert Bosch Gmbh | Electric machine in a motor vehicle having a rotational speed signal input |
| US20160241156A1 (en) * | 2013-12-03 | 2016-08-18 | Mitsubishi Electric Corporation | Power conversion apparatus |
| US9998024B2 (en) * | 2013-12-03 | 2018-06-12 | Mitsubishi Electric Corporation | Power conversion apparatus |
| US20160126205A1 (en) * | 2014-11-04 | 2016-05-05 | Toyota Jidosha Kabushiki Kaisha | Semiconductor device and manufacturing method for the semiconductor device |
| US9847311B2 (en) * | 2014-11-04 | 2017-12-19 | Toyota Jidosha Kabushiki Kaisha | Semiconductor device and manufacturing method for the semiconductor device |
| US20210327811A1 (en) * | 2020-04-20 | 2021-10-21 | Sungrow Power Supply Co., Ltd. | Inverter, And Power Unit And Power Module Applied Thereto |
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Also Published As
| Publication number | Publication date |
|---|---|
| JP4127550B2 (en) | 2008-07-30 |
| JP2006340569A (en) | 2006-12-14 |
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